How To Diagnose and Replace Battery on 2005 Vw Beetle Tdi

Explains the steps and prodedures that a do-it-yourselfer can fix it himself and save MONEY on professional repairs; namely, diagnosing and replacing a storage battery (out-of-vehicle) on a 2005 VW Beetle TDI

Step 1  

Place the gear selector in Park or First gear.

Step 2  

Place wheel chocks behind the rear wheels.

Step 3  

Pull the hood lever in the cabin compartment.

Step 4  

Pull the outside hood cable toward you and raise hood.

Step 5  

Place a memory keeper device in the accessory socket in the cabin compartment (Figure B-1).

Step 6  

Press the tab on the top battery cover and remove.

Step 7  

Press the tab on the fuse box and lift cover off (Figure B-2)

Step 8  

Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet, remove POSITIVE cable to fuse box (Figure B-3)

Step 9  

Step 10  

Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet, remove the NEGATIVE cable of the battery post (Figure B-4).

Step 11  

Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet, remove the clamp to the POSITIVE cable of the battery post (Figure B-5).

Step 12  

Detach the clamp on the battery cover (Figure B-6)

Step 13  

Using a flat-blade screwdriver, disengage the tabs that secure the battery cover to the battery tray (Figure B-7).

Step 14  

Remove battery cover and set aside.

Step 15  

Using a 3/8-inch square drive 13mm socket and 3/8-inch square drive ratchet, and 18-inch 3/8-inch square drive extension remove the battery hold-down bolt and bracket (Figure B-8).

Step 16  

The battery hold-down bolt and bracket removed as shown in Figure B-9.

Step 17  

Using battery strap (attached to battery), remove the storage battery from vehicle and place on work bench for testing.

Step 18  

The electrolyte level is tested in the cells of the battery before it is checked.

Step 19  

Remove the battery filler caps (6) from their cells.

Step 20  

Place a battery hydrometer in one (1) of the cells.

Step 21  

The reading on the scale of the hydrometer should be approximately 1.270.

Step 22  

This reading indicates the battery is fully charged (Figure B-10).

Step 23  

A lower reading would indicate the battery needs to be charged before testing.

Step 24  

Cells checked low are filled with distilled water only.

Step 25  

Fill cells that are low to the filler line with distilled water above the top plate. Do not overfill.

Step 26  

Using a typical battery charger, place the selector switch on the 2-amp or 10-amp setting.

Step 27  

Place the POSITIVE (red) cable of the battery charger to the POSITIVE post of the battery.

Step 28  

Place the NEGATIVE (black) cable of the battery charger to the NEGATIVE post of the battery.

Step 29  

Set the battery charger to the 2-amp (slow charging) setting. Charge the battery for seventy-two (72) hours to bring the battery to a full charge (Figure B-11).

Step 30  

Using a digital multi-meter (DMM)(available at auto parts stores) set the selector switch to the VOLTS setting.

Step 31  

Place the red test lead into the red jack of the DMM.

Step 32  

Place the black test lead into the COM jack of the DMM.

Step 33  

Place the other end of the red test lead and attach to POSITIVE post of the battery.

Step 34  

Place the other end of the black test lead and attach to NEGATIVE post of the battery.

Step 35  

The reading on the display of the DMM should range from 1.250 to 1.275 volts indicating the battery is fully charged.

Step 36  

This test (open circuit voltage) only indicates that the battery can hold a charge (Figure B-12).

Step 37  

A battery is accurately checked for capacity and strength with a battery load tester. A load tester evaluates the ability of the battery to operate the vehicle starter motor or accessories, and maintain the LOAD for fifteen (15) seconds with the voltage not going below 9.6 volts. A battery incapable of holding that voltage LOAD is defective (Figure B-13)

. The load test showed the Beetle storage battery to be defective.

Step 38  

The replacement battery should have the same specifications and dimensions as the the original or dead battery; namely, amperage rating and cold cranking rating.

Step 39  

Clean the battery POSITIVE and NEGATIVE posts and cables with a battery post brush (Figure B-14).

Step 40  

Step 41  

Stubborn corrosion on the battery cables should be cleaned with baking soda and water.

Step 42  

Place the replacement battery in the vehicle battery tray.

Step 43  

Install the battery hold-down bolt and bracket, cover, fuse box bolt, and top battery cover in the reverse order from which they were removed.

Step 44  

Remove the battery memory keeper from the accessory socket.

Step 45  

Remove the wheel chocks from under the rear wheels.

Step 46  

Test drive the Beetle for proper operation.

Tips

• A battery memory keeper is used by technicians' and do-it-yourselfers to retain the information in the ROM memory of the ECM from being lost when the negative cable of the battery is removed.
• A digital multi-meter is electronic test equipment that is used by technicians' to search for and diagnose electrical problems in electrical circuits of a vehicle.
• A battery that is discharged can be caused by a defective alternator. To test the altenator, set the DMM to the VOLTS setting. Place the red lead of the DMM to the POSITIVE post of the battery. Place the black test lead of the DMM to the NEGATIVE post of the battery. Attain a throttle speed of 1500rpm's with the engine running. The display on the DMM should read 15 to 17 VOLTS. This reading would indicate that the alternator is charging the battery. A reading of battery voltage (12.5 VOLTS) would indicate an alternator defect; such as, a defective diode bridge.
• When a vehicle is not driven daily or not driven for over a week, a battery maintainer should be installed to the battery posts. The maintainers POSITIVE and NEGATIVE cables are installed to the POSITIVE and NEGATIVE posts of the battery. It is a device that uses a computer chip that keeps a storage batterys cells from becoming a victim of sulphation. It reverses sulphation which is the main cause of battery failure.
• When a battery charger is needed to recharge a storage battery, do not set the charge rate for more than 10 amperes. Fast charging a battery will generate excessive heat in the cells and shorten the life of the storage battery.

Warnings

• When working around an automotive storage battery, always wear SAFETY GLASSES.
• Practive good lifting techniques (bending knees) to avoid injury when removing the storage battery from the vehicle. The battery is heavy.

Things You'll Need

• Tools and Equipment
• Flat-blade screwdriver
• Memory keeper
• Wheel chocks
• Battery charger
• Digital multi-meter (DMM)
• Battery hydrometer
• 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet.
• 3/8-inch square drive 13mm socket and 3/8-inch square drive ratchet.
• Safety glasses
• Battery load tester
• Replacement battery